Electrical reed relay having plug-in features



Aug. 31, 1965 w. F. BARTON 3,204,053

ELECTRICAL REED RELAY HAVING PLUG-IN FEATURES Filed Sept. 19. 1962United States Patent 3,204,058 ELECTRICAL REED RELAY HAVING PLUG-INFEATURES William Forbes Barton, Winnetlra, Ill., assignor to StandardGrigsby Inc., a corporation of Delaware Filed Sept. 19, 1962, Ser. No.224,779 7 Claims. (Cl. Mitt-87) This invention relates to a so-calledreed relay of the type having a switch formed of two elongated contactmembers of magnetic material enclosed within a tube of insulatingmaterial such as glass and projecting toward each other from oppositeends of the tube in cantilever fashion and into overlapping relation oftheir adjacent ends. The overlapping ends are shifted into and out ofconducting engagement with each other in response to selective directcurrent energization of a coil encircling the tube and the overlappingends.

The primary object of the invention is to construct a relay of the abovecharacter in a novel manner to facilitate connection of the contacts andcoil into electrical circuits and replacement of the relay in the eventof a malfunction.

Another object is to enclose the reed switch and coil as parts of acartridge having spaced exterior contact members adapted to interfitreleasably with clips or other parts providing electrical connectionswhile avoiding the use of solder.

A more detailed object is to enclose the switch and coil in a tube ofinsulating material having spaced exterior conductor members connectedto the contacts and coil terminals and interfitting with clips so as tosupport the parts as well as provide electrical circuit connections.

The invention also resides in the novel construction and arrangement ofparts permitting operation of the switch from a source of alternatingcurrent.

Other objects and advantages of the invention will become apparent fromthe following detailed description taken in conjunction with theaccompanying drawings in which:

FIGURE 1 is an exploded perspective view of a cartridge embodying thenovel features of the present invention and a clip mounting for thecartridge.

FIG. 2 is a side elevational view of the cartridge with some of theparts broken away and shown in section along a diametrical plane.

FIG. 3 is an exploded perspective view of the cartridge parts.

The reed switch shown in the drawings to illustrate the presentinvention comprises two reeds or elongated flap strips 11 of conductingmaterial which are supported by and enclosed within a hollow tube 12 ofinsulating material such as glass. The ends of the tube are sealedaround the respective reeds which are supported thereby in cantileverfashion and project toward each other from the tube ends and intooverlapping relation. In switches of this character, the reeds normallyare biased into normally closed positions of engagement with each otheror into spaced normally open positions, the reeds in this instance beingof the normally open type in which the biasing force is the resilienceof the reed material and the reeds are positioned initially with theiroverlapping end portions 13 spaced apart the desired distance.

Bias for shifting the overlapping end portions of the reeds 11 relativeto each other and out of their normal positions is derived from anelectromagnetic coil 14 encircling the insulating tube 12 and theoverlapping end portions 13. At least a part of these end portions, orpreferably the entire reeds as in this instance, are magnetic so thatmagnetic flux resulting from direct current energization of the coilthreads a path extending longitudinally through one reed, across the gapbetween the 3,204,058 Patented Aug. 31, 1965 reeds, and thenlongitudinally through the other reed. With such flux, the reeds tend toshift into contact to close the gap. As is well known in the art, anadditional initial magnetic bias may be provided, for example, byanother coil (not shown), to urge the reed ends into a normally closedcontact relation. With this arrangement, the main coil 14 is arranged sothat flux resulting from its energization opposes the biasing flux topermit the reed ends to separate.

In the use of reed relays of the above character, it has been customaryheretofore to mount the coil 14 on the exterior of the insulating tube12 with the coil terminals 15 and 16 exposed and outer end portions 17of the reeds extending beyond the ends of the tube. Electricalconnection to the reeds and coil terminals normally was made bysoldering conductors to these parts. Replacement of a relay so connectedinto electrical circuits required first that the solder connections bebroken and secondly that new solder connections be made with thecorresponding parts of the replacement relay. Not only did this involvesubstantial time and labor, but also, it required ready availability ofsoldering tools such as electrical soldering irons and electric powerfor operating the tools. It also was necessary to provide some device inaddition to the solder connections for supporting the reed relays.

In accordance with the present invention, the foregoing difficultieshave been overcome by a novel mounting of the reed relay parts both tofacilitate initial connection of the relay into electrical circuits andto enable the relay to be disconnected and replaced quickly and easilywithout the provision of special tools. To this end, the relay parts areenclosed as part of a cartridge 18 having spaced external terminalmembers 19 and 20 connected to the respective relay parts and adaptedfor snap-on removable connection with clips 21 or similar connecting andsupporting parts permanently connected into the electrical circuits. Thelocations of the external terminal members are correlated with thelocations and arrangement of the clips so that the cartridge may simplybe inserted manually into releasable locating engagement with the clipsand easily removed from such engagement manually and without any toolsin the event it is desired to replace the relay. More specifically, theinvention contemplates securing the reeds 11, their insulating tube 12and coil 14 with another tube 22 of insulating material having terminalmembers 19 and 20 in the form of encircling rings secured at spacedpoints along its exterior and connected respectively to the exposed reedend portions 17 and coil terminals 15 and 16. The entire cartridge thenis of generally cylindrical shape and is especially suited forreleasable connection with spring clips 21 of conducting material ofU-shape mounted on a support 23 of insulating material and opening inthe same direction at spacings corresponding to the spacings of therings so as to receive the latter individually while maintaining theirinsulation from each other.

The outer insulating tube 22 in the present instance is generallycylindrical in shape and is formed of a suitable insulating materialsuch as phenolic resin. Axially spaced circumferential sections of thetube are of smaller diameter than adjacent sections to provide recessesas indicated at 24 to receive the respective terminal rings 19 and 20and locate the same in spaced positions along the tube. Apertures 25opening through the innermost two of these recesses receive therespective terminals 15 and 16 of the coil 14 which are connected to theinner two terminal rings 19 in the recesses as by solder joints 26. Tofacilitate assembly of these inner rings on the tube, the rings aresplit to permit their expansion to a size large enough to telescope overthe larger diameter ridges 27 between the ring recesses. Also, each ringis recessed at 3 its ends as indicated at 19a to provide an apertureregistering with the tube aperture 25. The solder 26 connecting the coilterminals to the split rings serves to fill these recesses and securethe ends of the rings together with the rings tightened around the tubeand held in place by abutment with the ridges.

The outer two terminal rings 2th preferably are cylindrical side wallsof cups 28 which fit into the recesses 24 at the ends of the outerinsulating tube 22 with the bottoms 29 of the cups abutting and closingthe open ends of the tube. To retain the cups against the tube endswhile facilitating connection of the cups to the respective reeds 11,the outer end portions 17 of the reeds are flattened and extend intoelongated slots in the bottom walls of the cups. After their extensionthrough the slots the flattened ends are soldered to the cup bottomWalls to complete the connection between the reeds and the cups whilemaintaining the cups in position against the tube ends. To maintainproper relation of the parts Within the outer insulating tube, spacesaround these parts preferably are filled with a potting compound 31 suchas epoxy resin.

The coil 14 is wound on a spool having end flanges 32 and a central bore33 which telescopingly receives the glass tube 12. To center the spoolin the outer tube 22 and still permit the potting compound 31 to flowpast the coil end flanges, the latter are formed as squares with cornersrounded on a diameter equal approximately to the inner diameter of thetube and with flat edges spaced apart a distance less than the tubediameter, the outer diameter of the coil 14 being equal to or less thanthe spacing of the edges of the flanges.

In the present instance the closed end of each clip 21 is flat and issecured as by a rivet or bolt (not shown) against one side of theinsulating support 23 which is a flat board. Electrical connections maybe made by soldering conductors to the clips or to the securing rivet orbolt in a manner well known in the art. The clips are spaced apart onthe board distances corresponding to the axial spacing of the terminalrings 19 and 219 on the cartridge 18 and the upper end portions 34 ofthe spaced legs of each clip are curved to complement the shape of theterminal rings on the cartridge. The clips are formed of resilientconducting metal and spacing of the curved end portions of each clip isslightly less than the outer diameter of the terminal rings so that thelegs must be separated from their normal positions to receive and permitremoval of the cartridge While being urged toward each other due totheir resilience to grip the terminal rings and hold the cartridgeagainst movement out of the clips. To insure proper contact between eachclip and the associated terminal ring even though the width of the legsof each clip is different than the axial length of the rings, the outerdiameter of each ring is slightly less than the outer diameter of theadjacent ridges 27 of the outer insulating tube 22 so that the rings areraised slightly as shown in FIG. 2.

Assuming that the reeds 11 have been assembled Within their enclosingtube 12 with the ends of the latter clamped around the reeds, the nextsteps in assembly of the cartridge 18 are to insert that tube into thebore 13 of the coil spool and then insert this sub-assembly into theouter insulating tube 22 to bring the coil terminals and 16 intoregistry with the apertures in the outer tube. In the event the coilterminals are long enough, they may be threaded through the aperturesprior to insertion of the spool. In View of the correlation of thediameter of the corners of the spool flanges 32 with the inner diameterof the outer tube, the spool is centered automatically in coaxialrelation with the tube. Next, the split rings 19 are telescoped over theouter ridges 27 and are permitted to contract into their recesses 24with the ends of the rings adjacent the outer tube apertures 25. Thesolder connections 26 then are made to join the coil terminals to thesplit rings and to secure the ends of the latter together. I

It will be understood that, in the event the cartridge also is toinclude the resistor, capacitor and rectifier elements 35, 36 and 37 theconnections between these parts and the coil will be made prior toinsertion of the parts including the coil into the outer tube, theappropriate conductors being connected with the inner terminal ringsafter the parts are inserted the same as when no rectifying elements areused.

Once the parts have been inserted Within the outer insulating tube 22and the connections have been made to the split inner terminal rings 19,one of the end cups 28 is telcscoped over one end of the outer tube withone flat end portion 17 of the adjacent reed 11 projecting into the slot30 in the cup and the solder connection is made between the bottom wallof the cup and this flat end portion. The partially assembled cartridgeis then supported with its open end up and the potting compound 31 ispoured into that end to fill the space around the parts within the outertube. The compound flows easily past the coil and flanges due to theshape of the flanges 32 which provide clearance for the compound to flowfrom one end of the tube to the other. Finally, the other end cup istelescoped over the remaining open end of the tube to extend the otherreed end portion into the slot and the solder connection is made to jointhe reed and the bottom wall of the cup.

It will be apparent that, once the parts are assembled into thecartridge 18 with the appropriate connections to the terminal rings 19and 2d, the cartridge may be inserted in the clips 21 with the latterengaging the terminal rings. The cartridge thereby is connected simplyand easily into electric circuits previously connected to the clips. Inthe event the cartridge is to be replaced, it is simply pulled manuallyfrom between the curved clip legs 34 and a replacement cartridge isreinserted between the legs. No soldering or tools are required to makethe replacement. By virtue of its enclosure within the cartridge, therelay also is protected from injury due to contact with externalobjects.

I claim:

1. An electrical relay cartridge having, in combination, a firstelongated tube of insulating material open at opposite ends and havingtwo radial openings spaced therealong from each other and from the endsthereof, a hollow spool of insulating material disposed within saidfirst tube and having flanges engaging the interior thereof to locate acentral bore of the spool in coaxial relation with said first tube, areed relay element comprising a second tube of insulating material lyingcoaxially within said central bore of said spool and a pair of reeds ofconducting material projectin toward each other in cantilever fashionfrom opposite ends of the second tube and overlapping at adjacent endstherewithin, a coil wrapped around and supported by said spool betweensaid flanges and encircling said overlapping ends of said reeds, saidcoil and portions of said flanges being spaced from the interior of saidfirst tube to provide clearance for the flow of liquid filling materialpast said spool, cups of conducting material closing and secured aroundsaid open ends of said first tube and having central apertures, theother ends of said reeds extending outwardly away from each other andsaid second tube and through said apertures in said cups, means securingeach of said other reed ends to the adjacent one of said cups, rings ofconducting material encircling and secured to said first tube adjacentsaid radial openings therein and spaced along said first tube from eachother and said cups, said coil having terminals each connected to adifferent one of said rings through the adjacent one of said radialopenings, and a body of insulating material filling the spaces withinsaid first tube and around said relay element, said spool and said coil.

2. An electrical relay cartridge having, in combination, a firstelongated tube of insulating material, a hollow spool of insulatingmaterial disposed within said first tube and having flanges, saidflanges having regions engaging the interior thereof to locate a centralbore of the spool along the axis of said first tube, a reed relayelement comprising a second tube of insulating material lying withinsaid central bore of said spool and a pair of reeds of conductingmaterial projecting toward each other in cantilever fashion fromopposite ends of the second tube and overlapping at adjacent endstherewithin, a coil wrapped around and supported by said spool betweensaid flanges and encircling said overlapping ends of said reeds, saidcoil having terminals and the coil end portions of said flangesincluding other regions spaced from the interior of said first tube toprovide clearance for the flow of liquid filling material past saidspool, terminal members of conducting material secured to the exteriorof said first tube at spaced points along said first tube and insulatedfrom each other, said coil terminals and said reeds each being connectedto a different one of said terminal members, and a body of insulatingmaterial filling the spaces within said first tube and around said relayelement, said spool and said coil.

3. An electrical relay cartridge having, in combination, a firstelongated tube of insulating material open at opposite ends and havingtwo radial openings spaced therealong from each other and from the endsthereof, a hollow spool of insulating material disposed within saidfirst tube and having flanges engaging the interior thereof to locate acentral bore of the spool in coaxial relation with the said first tube,a reed relay element comprising a second tube of insulating materiallying coaxially within said central bore of said spool and a pair ofreeds of conducting material projecting toward each other in cantileverfashion from opposite ends therewithin, a coil Wrapped around andsfipported by said spool between said flanges and encircling saidoverlapping ends of said reeds, cups of conducting material closing andsecured around said open ends of said first tube and having centralapertures, the other ends of said reeds extending outwardly away fromeach other and said second tube and through said apertures in said cups,means securing each of said other reed ends to the adjacent one of saidcups, and rings of conducting material encircling and secured to saidfirst tube adjacent said radial openings therein and spaced along saidfirst tube from each other and said cups, said coil having terminalseach connected to a different one of said rings through the adjacent oneof said radial openings.

4. The combination of a first elongated tube of insulating material, areed relay element comprising a cylindrical material, a reed relayelement comprising a cylindrical tube of insulating material extendingalong the axis of said first tube and enclosing a pair of reeds ofconducting materal which project into overlapping relation with eachother in cantilever fashion from opposite ends of the second tube, acoil encircling said second tube and overlapping portions of said reedswithin said first tube and having terminals, four rings of conductingmaterial encircling and secured to said first tube at spaced pointsalong the length thereof, electrical connections within said first tubeinsulated from each other and joining each of said reeds and therespective terminals of said coil with a different one of said rings, aflat supporting member of insulating material and four clips ofresilient conducting material of U-shape spaced apart distancescorresponding to the spacing of said rings and each having a closed endportion secured to said supporting member and leg portions complementaryto the shape of said rings and normally spaced apart a distance lessthan the diameter of the rings whereby each of the legs of each clipreceive and frictionally grip a different one of rings in electricalconducting relation.

5. The combination of claim 4 in which said rings project radially andoutwardly beyond said first tube to insure contact of each ring withsaid legs of the associated one of said clips in spite of variations inthe widths of the clip legs.

6. An electrical relay having, in combination, a first elongated tube ofinsulating material, a reed relay element comprising a tube ofinsulating material extending along the axis of said first tube andenclosing a pair of reeds of conducting material which project intooverlapping relation with each other in cantilever fashion from oppositeends of the second tube, a coil encircling said second tube andoverlapping portions of said reeds within said first tube and havingterminals, rings of conducting material encircling and secured to saidfirst tube at spaced points along the length thereof, electricalconnections within said first tube insulated from each other and joiningeach of said reeds and the respective terminals of said coil with adifferent one of said rings, and a body of insulating material fillingthe spaces within said first tube around said element and saidconnections.

7. An electrical relay having, in combination, a first elongated tube ofinsulating material, a reed relay element comprising a tube ofinsulating material extending along the axis of said first tube andenclosing a pair of reeds of conducting material which project intooverlapping relation with each other in cantilever fashion from oppositeends of the second tube, a coil encircling said second tube andoverlapping portions of said reeds within said first tube and havingterminals, rings of conducting material encircling and secured to saidfirst tube at spaced points along the length thereof, and electricalconnections within said first tube insulated from each other and joiningeach of said reeds and the respective terminals of said coil with adifferent one of said rings.

References Cited by the Examiner UNITED STATES PATENTS BERNARD A.GILHEANY, Primary Examiner.

ROBERT K. SCI-IAEFER, Examiner.

1. AN ELECTRICAL REALY CARTRIDGE HAVING, IN COMBINAL TION, A FIRSTELONGAWTED TUBE OF INSULATING MATERIAL OPEN AT OPPOSITE ENDS AND HAVINGTWO RADIAL OPENINGS SPACED THEREALONG FROM EACH OTHER AND FROM THE ENDSTHEREOF, A HOLLOW SPOOL OF INSULATING MATEIRAL DISPOSED WITHIN SAIDFIRST TUBE AND HAVING FLANGER ENGAGING THE INTERIOR THEREOF TO LOCATE ACENTRAL BORE OF THE POOL IN COAXIAL RELATION WITH SAID FIRST TUBE, AREED RELAY ELEMENT COMPRISING A SEDCOND TUBE OF INSULATING MATERIALLYING COAXIALLY WITHIN SAID CENTRAL BORE OF SAID SPOOL AND A PAIR OFREEDS OF CONDUCTING MATERIAL PROJECTING TOWARD EACH OTHER IN CANTILEVERFASHION FROM OPPOSITE ENDS OF THE SECOND TUBE AND OVERLAPING AT ADJACENTENDS THEREWITHIN, A COIL WRAPPED AROUND AND SUPPORTED BY SAID POOLBETWEEN SAID FLANGES AND ENCIRCLING SID OVERLAPPING ENDS OF SAID REEDSAND COIL AND PORTIONS OF SAID FLANGES BEING SPECED FROM THE INTERIOR OFSAID FIRST TUBE TO PROVIDE CLEARANCE FOR THE FLOW OF LIQUID FILLINGMATERIAL PAST SAID SPOOL, CUPS OF CONDUCTING MATERIAL CLOSING ANDSECURED AROUND SAID OPEN ENDS OF SAID FIRST TUBE AND HAVING CENTRALAPERTURES, THE OTHER ENDS OF SAID REEDS EXTENDING OUTWARDLY AWAY FROMEACH OTHER AND SAID SECOND TUBE AND THROUGH SAID APERTURES IN SAID CUPS,MEANS SECURING EACH OF SAID OTHER REED ENDS TO THE ADJACENT ONE OF SAIDCUPS, RINGS OF CONDUCTING MATERIAL ENCIRCLING AND SECURED TO SAID FIRSTTUBE ADJACENT SID RADIAL OPENINGS THEREIN AND SPACED ALONG SAID FIRSTTUBE FOR EACH OTHER AND SAID CUPS, SAID COIL HAVING TERMINALS EACHCONNECTED TO A DIFFERENT ONE OF SAID RINGS THROUGH THE ADJACENT ONE OFSAID RADIAL OPENINGS AND A BODY OF INSULATING MATERIAL FILLING THESPECES WITHIN SAID FIRST TUBE AND AROUND SAID RELAY ELEMENT, SAID SPOOLAND SAID COIL